Systems and methods for forming magnet wire insulation with thermoset material

Abstract

Systems and methods for forming insulation on magnet wire are provided. An extruder that includes one or more rotating screws may receive a thermoset polymeric material and process the thermoset polymeric material to increase its pressure and temperature. An extrusion crosshead assembly in fluid communication with the extruder may receive the thermoset polymeric material and press extrude the thermoset polymeric material as insulation onto a magnet wire. A curing device may then cure the extruded insulation material.

That which is claimed: 
     
       1. A method for forming insulation on a winding wire, the method comprising:
 providing, to an extruder comprising one or more rotating screws, a thermoset polymeric material containing less than thirty percent by weight of solvent; 
 processing the thermoset polymeric material within the extruder to increase its temperature and pressure; 
 press extruding the thermoset polymeric material as insulation on a magnet wire; and 
 curing the extruded insulation material. 
 
     
     
       2. The method of  claim 1 , wherein providing a thermoset polymeric material comprises providing a thermoset polymeric material as a powder. 
     
     
       3. The method of  claim 1 , wherein providing a thermoset polymeric material comprises providing a thermoset polymeric material in a solution containing less than twenty percent by weight of solvent. 
     
     
       4. The method of  claim 1 , wherein providing a thermoset polymeric material comprises:
 providing a plurality of ingredients for the thermoset polymeric material to the extruder; and 
 processing the plurality of ingredients within the extruder to facilitate polymerization of the thermoset polymeric material. 
 
     
     
       5. The method of  claim 1 , wherein providing a thermoset polymeric material comprises providing one of (i) polyimide, (ii) polyamide, or (iii) polyamide imide. 
     
     
       6. The method of  claim 1 , wherein press extruding the thermoset polymeric material comprises extruding the thermoset polymeric material as a paste, a slurry, or as a semi-solid. 
     
     
       7. The method of  claim 1 , further comprising:
 removing one or more unwanted substances from the extruder via vacuum devolatilization. 
 
     
     
       8. The method of  claim 1 , further comprising:
 filtering the thermoset polymeric material prior to press extruding the thermoset polymeric material. 
 
     
     
       9. The method of  claim 1 , further comprising:
 adding one or more filler materials to the extruder for mixing with the thermoset polymeric material prior to extrusion. 
 
     
     
       10. The method of  claim 1 , wherein curing the extruded insulation material comprises heat curing the extruded insulation material in an oven. 
     
     
       11. A method for forming insulation on a winding wire, the method comprising:
 providing, to an extruder comprising one or more rotating screws, a thermoset polymeric material containing less than thirty percent by weight of solvent; 
 processing the thermoset polymeric material within the extruder to increase its temperature and pressure; 
 press extruding the thermoset polymeric material as insulation on a magnet wire; and 
 processing the magnet wire with a curing device that cures and further removes solvent from the extruded thermoset polymeric material. 
 
     
     
       12. The method of  claim 11 , wherein providing a thermoset polymeric material comprises providing a thermoset polymeric material as a powder. 
     
     
       13. The method of  claim 11 , wherein providing a thermoset polymeric material comprises:
 providing a plurality of ingredients for the thermoset polymeric material to the extruder; and 
 processing the plurality of ingredients within the extruder to facilitate polymerization of the thermoset polymeric material. 
 
     
     
       14. The method of  claim 11 , wherein providing a thermoset polymeric material comprises providing one of (i) polyimide, (ii) polyamide, or (iii) polyamide imide. 
     
     
       15. The method of  claim 11 , wherein press extruding the thermoset polymeric material comprises extruding the thermoset polymeric material as a paste, a slurry, or as a semi-solid. 
     
     
       16. The method of  claim 11 , further comprising:
 removing one or more unwanted substances from the extruder via vacuum devolatilization. 
 
     
     
       17. The method of  claim 11 , further comprising:
 filtering the thermoset polymeric material prior to press extruding the thermoset polymeric material. 
 
     
     
       18. The method of  claim 11 , further comprising:
 adding one or more filler materials to the extruder for mixing with the thermoset polymeric material prior to extrusion. 
 
     
     
       19. The method of  claim 11 , wherein processing the magnet wire with a curing device comprises processing the magnet wire in an oven. 
     
     
       20. A system for forming insulation on magnet wire, the system comprising:
 an extruder comprising one or more rotating screws, wherein the extruder is adapted to receive a thermoset polymeric material containing less than thirty percent solvent by weight and process the thermoset polymeric material to increase its pressure and temperature; 
 an extrusion crosshead assembly in fluid communication with the extruder and adapted to press extrude the thermoset polymeric material as insulation onto a magnet wire; and 
 a curing device adapted to cure the extruded insulation material and further remove solvent from the extruded insulation material.